Metal exoskeleton polymer composite material building template and manufacturing method thereof

Abstract

The invention provides a metal exoskeleton polymer composite material building template and a manufacturing method, the metal exoskeleton polymer composite material building template comprises a metal mesh and a metal panel which are oppositely distributed, middle stand columns are arranged on the periphery between the metal mesh and the metal panel, and corner stand columns are arranged between the metal mesh and the corners of the metal panel; and a polymer composite material is filled between the metal mesh and the metal panel. The product is provided with recycled metal components and high polymer materials, so that the social environment burden is reduced, low-cost manufacturing is realized, better social benefits can be created, considerable economic benefits can be brought to enterprises, and the product has excellent quality guarantee and safety performance. Due to the high bending resistance characteristic, compatibility with an aluminum alloy formwork system commonly adopted in the current market is guaranteed, and the capacity of replacing part of materials is achieved. In the concrete pouring process, the formwork system has high safety reserve, the phenomenon of formwork explosion or formwork expansion rarely occurs, and fire disasters are not prone to being caused.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, specifically to a metal exoskeleton polymer composite material building template and its manufacturing method. Background Technology

[0002] Currently, different types of polymer composite material formwork have emerged in the domestic construction market. These formworks are mostly made of polymer resin materials such as PP, PE, or ABS, reinforced with glass fiber. These products share the characteristics of being lightweight, having a much higher structural bending stiffness than wooden formwork, and being significantly smaller than steel and aluminum alloy formwork. Furthermore, they are reusable and recyclable. In recent years, these products have been widely used in municipal engineering and building construction, becoming a new type of green building material that can replace wooden, steel, and aluminum alloy formwork.

[0003] However, these products also have several significant drawbacks. First, their flexural strength is clearly insufficient, making them prone to deformation or damage during construction. Second, the overall fire resistance of the structure has not been well addressed; in the event of a fire, it can accelerate the combustion and destruction of the material, potentially leading to safety accidents. Finally, during use, the outer edge structure of the product is susceptible to falling and damage, frequently resulting in instances of formwork bursting or bulging during concrete pouring at construction sites. Furthermore, incidents of material fires also occur from time to time, making the market application and promotion of these products face significant obstacles and risks.

[0004] Traditional methods for improving the flexural strength of polymer composites involve increasing the material thickness or height of the structure. However, this design approach increases product weight and manufacturing costs significantly, making it a less than ideal solution. Furthermore, traditional methods for enhancing flame retardancy primarily involve adding chemical flame retardants to the polymer, often in high proportions. However, adding chemical flame retardants significantly reduces the mechanical properties of the composite material and also substantially increases manufacturing costs.

[0005] To address the issues of insufficient flexural strength and poor fire resistance of polymer composite building formwork, it is crucial to explore a simple, reliable, and low-cost manufacturing technology. Summary of the Invention

[0006] The purpose of this invention is to provide a metal exoskeleton polymer composite material building template and its manufacturing method to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: The present invention provides a metal exoskeleton polymer composite material building template, comprising the following steps:

[0008] It includes metal mesh sheets and metal panels distributed in a relatively opposite manner. The metal mesh sheets and metal panels are provided with central pillars around their perimeters, and corner pillars are provided between the corners of the metal mesh sheets and metal panels. The space between the metal mesh sheets and metal panels is filled with a polymer composite material.

[0009] Preferably, the metal mesh sheets are provided with multiple transverse ribs and longitudinal ribs, and the multiple transverse ribs and longitudinal ribs are distributed vertically.

[0010] Preferably, the metal panel, metal mesh, transverse ribs, longitudinal ribs, central column, and corner column interfaces are all welded together using metal materials.

[0011] Preferably, the metal panel, metal mesh, transverse ribs, and longitudinal ribs are provided with a number of holes and slots, and the holes and slots are mechanically punched and have flanges.

[0012] A method for manufacturing a polymer composite material building template for a metal exoskeleton includes the following steps:

[0013] Step 1: Selection of Metal Materials

[0014] Select metal sheets of appropriate thickness according to the dimensions required by the design drawings;

[0015] Step 2: Cutting and processing of metal parts

[0016] The selected sheet metal is cut using a shearing machine or plasma cutting machine to ensure that the product’s forming dimensions and flatness meet the design accuracy requirements. The metal panel and metal mesh are punched using a punching and flanging machine to ensure that the flanging dimensions meet the design requirements.

[0017] Step 3: Welding of metal components

[0018] The pre-processed metal parts are placed in the welding mold and welded according to the design requirements. The welding current is controlled and the matching welding rods are selected. Reliable metal welding deformation control technology is adopted to ensure that the shrinkage deformation and warpage of the product meet the design accuracy requirements.

[0019] Step 4: Preparation of Polymer Composite Materials

[0020] Adjusting and controlling the content of fiber-reinforced materials ensures that the coefficient of thermal expansion of the composite material is basically consistent with that of the metal component. When using injection molding, the polymer composite material is heated to 220 degrees in the screw press to form a highly fluid plastic fluid.

[0021] Step 5: Preheating of metal components

[0022] To ensure that the shrinkage and deformation of the polymer composite material and the metal component are consistent during product molding, and to reduce the internal stress and deformation of the structure after molding, the metal component needs to be preheated by resistance heating or oven heating, generally to 230 degrees Celsius.

[0023] Step 6: Injection molding or compression molding

[0024] A heated metal component is placed in the injection molding machine mold. After the mold is closed, high-pressure injection molding is performed, which causes the flowable polymer composite material to fill the mold cavity. The mold is then pressurized, allowed to stand, cooled, and demolded.

[0025] Step 7: Finished Product Shaping

[0026] After the product is demolded, it is immediately placed on the shaping tool table. It is then stacked in batches of 5 to 10 layers and pressure-shaped using a hydraulic press to eliminate residual stress and deformation inside the structure.

[0027] Preferably, the polymer composite material in step four comprises the following components: polymer matrix, filler, modifier, and reinforcing fiber.

[0028] Preferably, the contents of each component, by mass percentage, are as follows: polymer matrix 42%-50%, filler 9-15%, modifier 2-5%, and reinforcing fiber 40-50%.

[0029] Preferably, the reinforcing fiber is one or more of glass fiber, carbon fiber, boron fiber, whiskers, asbestos fiber, and metal fiber.

[0030] This invention has at least the following beneficial effects:

[0031] (1) The present invention provides a metal exoskeleton polymer composite building template and manufacturing method. The product has recyclable metal components and polymer materials, which helps to reduce the social and environmental burden and achieve low-cost manufacturing. It can not only create better social benefits, but also bring considerable economic benefits to enterprises.

[0032] (2) The present invention provides a metal exoskeleton polymer composite material building formwork and its manufacturing method. This product has excellent quality assurance and safety performance. Its high bending resistance ensures compatibility with the aluminum alloy formwork system commonly used in the current market and has the ability to replace some materials. During the concrete pouring process, this formwork system has a high safety reserve, rarely experiencing formwork bursting or bulging, and is less likely to cause fire.

[0033] (3) The present invention provides a metal exoskeleton polymer composite building template and its manufacturing method. This product uses high-quality metal material as the outer protective layer, which makes it have lower usage costs during use. At the same time, due to the excellent design of the product, it can significantly reduce the probability of drop damage during the demolding and transportation process, thereby greatly increasing the turnover rate of building templates and reducing the usage costs for enterprises. This product has good application prospects. Attached Figure Description

[0034] Figure 1 A schematic diagram of a polymer composite material building template structure for a metal exoskeleton provided by the present invention;

[0035] Figure 2 A schematic diagram of the polymer composite material building template metal mesh structure for the metal exoskeleton provided by the present invention;

[0036] Figure 3 A schematic diagram of the polymer composite material building template metal panel structure for the metal exoskeleton provided by the present invention;

[0037] Figure 4 This is a schematic diagram of the polymer composite material building template flange structure for the metal exoskeleton provided by the present invention.

[0038] In the attached diagram, the following are the reference numerals: 1. Metal panel; 2. Hole and groove; 3. Metal mesh; 31. Horizontal rib; 32. Longitudinal rib; 4. Central column; 5. Corner column; 6. Flanged edge. Detailed Implementation

[0039] To facilitate understanding of the present invention, the invention will be described in more detail below with reference to the accompanying drawings and specific embodiments. It should be noted that when an element is described as being "fixed to" another element, it can be directly on the other element or there can be one or more intermediate elements therebetween. When an element is described as being "connected to" another element, it can be directly connected to the other element or there can be one or more intermediate elements therebetween. The terms "upper," "lower," "inner," "outer," "bottom," etc., used in this specification indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the purpose of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the present invention. In addition, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0040] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used in this specification includes any and all combinations of one or more of the associated listed items.

[0041] Example

[0042] See Figures 1-4 In this embodiment, a metal exoskeleton polymer composite building template possesses excellent strength and durability, and is widely used in various construction projects. It mainly consists of metal mesh sheets 3 and metal panels 1 arranged in a relatively opposite pattern. Specifically, the thickness of the metal panels 1 is generally between 0.25mm and 1.0mm. Central columns 4 are provided around the metal mesh sheets 3 and metal panels 1 to provide additional support. Corner columns 5 are also provided between the corners of the metal mesh sheets 3 and metal panels 1 to enhance the stability of the template.

[0043] The core component of this building formwork is the polymer composite material filling the space between the metal mesh 3 and the metal panel 1. This material has excellent compressive strength and weather resistance, effectively protecting the formwork from the influence of the external environment. Simultaneously, multiple transverse ribs 31 and longitudinal ribs 32 are provided between the metal mesh 3. Specifically, the thickness of the transverse ribs 31 and longitudinal ribs 32 is generally 1.5mm to 3mm, and the width is generally 8mm to 12mm. These ribs not only increase the rigidity of the formwork but also make it more resistant to bending and torsion.

[0044] All the joints of these components are welded with metal materials, further enhancing the overall strength of the template. In addition, the metal panel 1, metal mesh 3, transverse ribs 31, and longitudinal ribs 32 are provided with several holes and slots 2. Specifically, the diameter of the holes and slots 2 is generally 5mm to 8mm, and the holes and slots 2 can be circular or rectangular. These holes and slots 2 are made by mechanical punching and are provided with flanges 6. Specifically, the height of the flanges 6 is generally 3mm to 5mm, so as to facilitate the connection with the polymer composite material by flange key interlocking.

[0045] In summary, this polymer composite building template with a metal exoskeleton not only possesses excellent mechanical properties, but also demonstrates extremely high durability and stability in practical applications, providing reliable support and protection for various construction projects.

[0046] In this embodiment, a metal-bonded interlocking structure is used to form a load-bearing whole from materials of different properties, fully utilizing the superior properties of each material in the product structure design. This product is designed as a composite rib structure, utilizing the excellent tensile strength of the metal mesh 3 on the outer flange of the rib structure under stress, thereby improving the overall bending strength of the building formwork structure. Laboratory tests have shown that the bending strength of the structure using the metal mesh can be increased by three to five times. The metal panel 1 significantly improves the product's wear resistance and fire resistance. Building formwork typically involves welding and cutting of metal materials on the load-bearing side. Ordinary polymer formwork can be directly burned through by welding sparks, easily causing a fire. The metal panel provides excellent protection for the polymer composite material, effectively isolating the fire source and making the product less prone to fire during use, achieving the goal of safe use. The load-bearing surface of the building formwork and the outer edges of the structural components are protected by metal materials, significantly reducing the probability of drop damage during formwork dismantling, significantly increasing the number of formwork reuses, and reducing usage costs.

[0047] A method for manufacturing a polymer composite material building template for a metal exoskeleton includes the following steps:

[0048] Step 1: Selection of Metal Materials

[0049] Select metal sheets of appropriate thickness according to the dimensions required by the design drawings;

[0050] Step 2: Cutting and processing of metal parts

[0051] The selected sheet metal is cut using a shearing machine or plasma cutting machine to ensure that the product’s forming dimensions and flatness meet the design accuracy requirements. The metal panel and metal mesh are punched using a punching and flanging machine to ensure that the flanging dimensions meet the design requirements.

[0052] Step 3: Welding of metal components

[0053] The pre-processed metal parts are placed in the welding mold and welded according to the design requirements. The welding current is controlled and the matching welding rods are selected. Reliable metal welding deformation control technology is adopted to ensure that the shrinkage deformation and warpage of the product meet the design accuracy requirements.

[0054] Step 4: Preparation of Polymer Composite Materials

[0055] Adjusting and controlling the content of fiber-reinforced materials ensures that the coefficient of thermal expansion of the composite material is basically consistent with that of the metal component. When using injection molding, the polymer composite material is heated to 220 degrees in the screw press to form a highly fluid plastic fluid.

[0056] Step 5: Preheating of metal components

[0057] To ensure that the shrinkage and deformation of the polymer composite material and the metal component are consistent during product molding, and to reduce the internal stress and deformation of the structure after molding, the metal component needs to be preheated by resistance heating or oven heating, generally to 230 degrees Celsius.

[0058] Step 6: Injection molding or compression molding

[0059] A heated metal component is placed in the injection molding machine mold. After the mold is closed, high-pressure injection molding is performed, which causes the flowable polymer composite material to fill the mold cavity. The mold is then pressurized, allowed to stand, cooled, and demolded.

[0060] Step 7: Finished Product Shaping

[0061] After the product is demolded, it is immediately placed on the shaping tool table. It is then stacked in batches of 5 to 10 layers and pressure-shaped using a hydraulic press to eliminate residual stress and deformation inside the structure.

[0062] The polymer composite material includes the following components: polymer matrix, filler, modifier, and reinforcing fiber. Specifically, the content of each component by mass percentage is as follows: polymer matrix 42%-50%, filler 9-15%, modifier 2-5%, and reinforcing fiber 40-50%.

[0063] These components are mixed together in a certain proportion to form this composite material with excellent properties.

[0064] Specifically, the polymer matrix is ​​the foundation of this material, providing it with flexibility, strength, and durability. Fillers, on the other hand, are substances used to increase the material's volume and reduce cost, improving its thermal conductivity and mechanical properties. Modifiers alter the material's surface properties and flowability, while reinforcing fibers are crucial components used to enhance its strength and stiffness.

[0065] More specifically, reinforcing fibers are the core component of this material, improving its mechanical properties and thermal stability. There are many types of reinforcing fibers, including glass fibers, carbon fibers, boron fibers, whiskers, asbestos fibers, and metal fibers. These fibers play a crucial role in the material; their addition significantly improves its strength and stiffness, while also enhancing its high-temperature resistance and corrosion resistance.

[0066] In this embodiment, the product is formed in one step using various materials of different properties under high temperature and pressure. The structure is simple, the process is not complex, and the quality of process components is easy to control and inspect, resulting in high bending resistance and good fire resistance that meet design requirements. The main working principle utilizes the superior tensile strength of metallic materials and the excellent flowability, plasticity, and good compressive strength of thermoplastic composite materials after molding. This product has promising application prospects.

[0067] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; under the concept of the present invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of the present invention as described above, which are not provided in detail for the sake of brevity; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A metal exoskeleton polymer composite building formwork, characterized by: It includes metal mesh (3) and metal panel (1) arranged in opposite directions. The metal mesh (3) and metal panel (1) are provided with central pillars (4) around their perimeter. Corner pillars (5) are provided between the corners of the metal mesh (3) and metal panel (1). The space between the metal mesh (3) and metal panel (1) is filled with polymer composite material.

2. The metal exoskeleton polymer composite building formwork according to claim 1, wherein, The metal mesh (3) is provided with multiple transverse ribs (31) and longitudinal ribs (32), and the multiple transverse ribs (31) and longitudinal ribs (32) are distributed vertically.

3. The metal exoskeleton polymer composite building formwork according to claim 2, wherein, The interfaces of the metal panel (1), metal mesh (3), transverse ribs (31), longitudinal ribs (32), central column (4), and corner column (5) are all welded with metal materials.

4. The metal exoskeleton polymer composite building formwork according to claim 1, wherein, The metal panel (1), metal mesh (3), transverse ribs (31), and longitudinal ribs (32) are provided with several holes and slots (2), and the holes and slots (2) are mechanically punched and have flanges (6).

5. A method for manufacturing a metal exoskeleton polymer composite building formwork, characterized by, Includes the following steps: Step 1: Selection of Metal Materials Select metal sheets of appropriate thickness according to the dimensions required by the design drawings; Step 2: Cutting and processing of metal parts The selected sheet metal is cut using a shearing machine or plasma cutting machine to ensure that the product’s forming dimensions and flatness meet the design accuracy requirements. The metal panel and metal mesh are punched using a punching and flanging machine to ensure that the flanging dimensions meet the design requirements. Step 3: Welding of metal components The pre-processed metal parts are placed in the welding mold and welded according to the design requirements. The welding current is controlled and the matching welding rods are selected. Reliable metal welding deformation control technology is adopted to ensure that the shrinkage deformation and warpage of the product meet the design accuracy requirements. Step 4: Preparation of Polymer Composite Materials Adjusting and controlling the content of fiber-reinforced materials ensures that the coefficient of thermal expansion of the composite material is basically consistent with that of the metal component. When using injection molding, the polymer composite material is heated to 220 degrees in the screw press to form a highly fluid plastic fluid. Step 5: Preheating of metal components To ensure that the shrinkage and deformation of the polymer composite material and the metal component are consistent during product molding, and to reduce the internal stress and deformation of the structure after molding, the metal component needs to be preheated by resistance heating or oven heating, generally to 230 degrees Celsius. Step 6: Injection molding or compression molding A heated metal component is placed in the injection molding machine mold. After the mold is closed, high-pressure injection molding is performed, which causes the flowable polymer composite material to fill the mold cavity. The mold is then pressurized, allowed to stand, cooled, and demolded. Step 7: Finished Product Shaping After the product is demolded, it is immediately placed on the shaping tool table. It is then stacked in batches of 5 to 10 layers and pressure-shaped using a hydraulic press to eliminate residual stress and deformation inside the structure.

6. The method for manufacturing a metal exoskeleton polymer composite material building template according to claim 5, characterized in that, The polymer composite material in step four includes the following components: polymer matrix, filler, modifier, and reinforcing fiber.

7. The method for manufacturing a metal exoskeleton polymer composite material building template according to claim 6, characterized in that, The content of each component by mass percentage is as follows: polymer matrix 42%-50%, filler 9-15%, modifier 2-5%, and reinforcing fiber 40-50%.

8. The method for manufacturing a metal exoskeleton polymer composite material building template according to claim 7, characterized in that, The reinforcing fiber is specifically one or more of glass fiber, carbon fiber, boron fiber, whiskers, asbestos fiber, and metal fiber.

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